Rapid Fire Damage Restoration enabled Continued Production at The Royal Mint’s Nickel Plating Plant
Case study from the archive · First published in 2015
May 2015: Following a fire in the nickel plating plant at The Royal Mint in Llantrisant, South Wales, BELFOR UK successfully restored a heavily smoke-damaged production facility without interrupting ongoing manufacturing operations. Through specialist fire damage restoration techniques, innovative decontamination technology, and meticulous project execution, the 48,000-square-foot plant was returned to operational condition on schedule and within budget.
Smoke Contamination Threatened a High-Volume Production Environment
The Royal Mint is the United Kingdom’s official coin manufacturer and one of the world’s leading export mints. Operating continuously throughout the year, the 35-acre site can produce up to 90 million coins per week. After a fire broke out within the production area, extensive smoke contamination affected the entire nickel plating plant. The building’s reinforced concrete structure prevented fire spread, but trapped large volumes of smoke throughout the facility.
The restoration challenge was further complicated by the plant’s approximately 50-foot-high roof structure and the requirement to maintain production activities below while recovery works were underway.
Specialist Access Solutions and Innovative Decontamination Methods
To safely reach contaminated surfaces throughout the facility, BELFOR designed and erected a complex internal “bird cage” scaffold structure featuring three working levels. The installation required approximately 12,000 scaffold boards and 9,000 tons of scaffold poles, enabling technicians to access elevated areas without disrupting critical operations.
Working conditions were particularly demanding due to the heat generated by operational manufacturing equipment. BELFOR implemented carefully managed crew rotations to maintain productivity while ensuring safe working practices and adherence to project timelines.
For the decontamination process, BELFOR deployed its proprietary Soot Removal Film (SRF) technology. Unlike traditional cleaning methods, SRF is wash-free, odourless, and environmentally friendly, eliminating the need for chemicals and allowing production processes to continue during restoration activities. More than 18,700 pounds of SRF were used to remove smoke residues and contamination from the facility.
Delivering Results in a Secure Industrial Environment
As a site protected by the Ministry of Defence Police, The Royal Mint operates under stringent security protocols. All BELFOR personnel underwent rigorous security screening before entering the facility, ensuring compliance with the site’s strict operational requirements throughout the project.
The restoration programme required more than 8,800 labour hours and was completed while supporting the client’s need for operational continuity. The combination of specialist fire damage restoration expertise, innovative decontamination technology, and effective project management enabled BELFOR to achieve the required recovery standards efficiently and cost-effectively.
A Successful Recovery Following Severe Smoke Damage
The Royal Mint’s technical leadership praised BELFOR’s response, highlighting the confidence provided from the first day of the project and the successful recovery achieved through professional techniques and extensive restoration expertise. The facility was restored in good time and within budget, demonstrating how effective fire damage restoration can minimise business interruption and help industrial organisations rapidly recover following a loss event.
